Complexity is the enemy of uptimeA technician arrives at your factory floor to service a critical machine, a routine task crucial for maintaining production flow. Instead of seamlessly connecting and getting to work, they are granted over-privileged access by network controls designed for a different era. Security measures, intended to protect your network, stall operations, and lead to production outages. This isn't the result of a malicious cyberattack; it's an internal access issue. And the problem is, security is getting in the way of operations. This common scenario begs the question: What if security didn’t just protect data, but actively enabled operational uptime? In manufacturing, uptime is now a cross-functional Key Performance Indicator (KPI) essential to operational outcomes, production, and revenue. As we all know, downtime isn't just inconvenient; it triggers real financial penalties tied to customer Service Level Agreements (SLAs), delayed shipments, or lost revenue. This article explores why outdated internal security patterns hold operations back. We’ll also highlight how security can become an enabler of uptime and lead to a shift in how we think about cybersecurity in manufacturing. When did security become the bottleneck?It can feel like security, specifically network segmentation and access control, has devolved into a reactive, ticket-driven bottleneck for both operations and IT teams. Let’s say you need to bring in a new vendor to work on a specific piece of machinery, or perhaps modify access for an internal team. What should be a relatively straightforward process often triggers a complex chain of events. You can't quickly onboard because granting them appropriate, limited access is cumbersome. Changes must be planned meticulously around inconvenient downtime windows, requiring multiple approvals and complex change controls. Here’s the irony: It's not primarily malicious external attackers who are being impeded by traditional security measures. More often than not, internal users are the ones getting blocked by the very architectures designed to protect the network. When did security stop being a protective layer and start becoming a drag on operations? It largely comes down to this: security models we're using today were designed for a time when networks were simpler and more centralized, dominated by office-based desktops and a predictable number of connected devices.They simply weren't created for today's highly interconnected, agile manufacturing floors, replete with diverse IoT/OT devices and remote access needs. This mismatch means that even basic security maintenance, like patching vulnerable legacy systems (and many OT devices run on legacy, end-of-life operating systems) frequently requires taking critical machinery offline. This directly causes production losses and risks violations of customer SLAs, turning security tasks into costly operational disruptions.While intended to protect, the security models manufacturers inherited have become rigid, complex systems that now actively hinder the speed and efficiency required for modern operations.Why legacy security models make complexity worseUptime isn't just an IT metric anymore. In modern manufacturing, it's mission-critical—a direct production and revenue issue. When the factory floor stops, it immediately impacts output and your bottom line. Yet the traditional security models that many manufacturers still rely on actively work against this need for constant operational continuity.Legacy security models inherently make complexity worse. This complexity arises from several sources: Overlapping segmentation rules, which become tangled and difficult to manageReliance on legacy VLANs and firewalls with rigid configurationOverall inflexible infrastructure that resists the need for dynamic changeA prime example of this complexity comes from legacy Network Access Control (NAC) systems, which force hardware refreshes and require rigid policies and manual access approvals. In fact, many factories face costly switch replacement cycles, not because the switches themselves are broken, but simply because their aging NAC tools require newer infrastructure to function. This is a clear instance where the security infrastructure dictates operational spending and capability in a negative way. The sheer complexity of these systems, particularly east-west firewalls, means segmentation projects often aren't fully completed or quickly suffer from policy drift. In this context, complexity equals fragility. The more complex your internal segmentation model, the more likely it is to fail, delay, or block the very operations that are now tied so tightly to your production and revenue.Connected operations need a different kind of security Today's manufacturing floor is a far cry from the simpler environments of the not-too-distant past. This interconnected landscape, while boosting efficiency, introduces significant new demands. In this new reality, third-party vendors regularly need access to service specific pieces of machinery, especially the legacy systems that require specialized support. Manufacturers are deploying more connected devices, from advanced IoT sensors to diverse OT systems. These devices and systems often require remote monitoring and might utilize predictive maintenance tools or vendor support tools that need network connectivity.This shift towards smart technology and connected operations is crucial for growth and operational efficiency, speedier supply chain fulfillment, and innovation. Compounding this, manufacturers must also comply with strict regulations. Standards such as ISO 27001, customer audit demands, or specific sector regulations are increasingly mandating strong internal security, even stretching across factory floors. This adds significant pressure to modernize your security posture, but it absolutely has to happen without disrupting critical uptime. Within this context, imagine trying to figure out what's happening when something goes wrong. Without integrated local visibility, responding to potential incidents becomes a major challenge. It means forcing escalations for even minor issues and significantly delaying how quickly you can contain a problem. The highly connected, uptime-sensitive, and compliance-driven world of modern manufacturing requires a security approach that can handle complexity, enable visibility, and prevent threats from spreading, all while keeping operations running smoothly.A mindset shift is the first step to modernizationWe've seen how legacy security models are actually adding complexity and fragility, becoming a bottleneck for mission-critical uptimeAddressing this gap starts not just with new technology, but with a crucial mindset shift. It's time to rethink what cybersecurity should do in a manufacturing environment.The traditional mindset often leads to security being seen as something that requires agent-based segmentation, centralized controls that may be far from the factory floor, and cumbersome manual access approvals for anyone needing legitimate access, like a vendor. The necessary shift is toward security that is fundamentally different. It should be invisible to operations and fast for IT. Instead of blocking or delaying, security needs to become an enabler of operational continuity. It shouldn't force you to schedule downtime just to manage internal segmentation or add layers of operational complexity. It’s important to recognize that incidents aren't always caused by external hackers. Security must be designed to prevent both malicious attacks and unintentional risks, such as configuration errors that occur during routine maintenance or service windows, which can accidentally expose parts of the network or disrupt production.New approaches exist that are designed precisely for today’s manufacturing environment. They offer a path to better security without requiring disruptive hardware overhauls or taking critical systems offline.Think about it this way: Every equipment refresh, vendor renewal, or network update is a chance to rethink how you secure operations. These moments are opportunities to implement security that aligns with your business goals of uptime and agility, rather than hindering them.Ask yourself—is your security helping or hindering uptime?Given the new reality of connected operations and the critical importance of uptime, it's worth taking a moment to honestly evaluate your current security approach. Consider these questions:Do security changes or requirements frequently delay your operations?Are you forced to schedule downtime windows just to implement or update internal segmentation policies?Are your current security tools and processes adding complexity rather than removing it from your environment?Are well-meaning internal employees or third-party technicians inadvertently introducing risks during maintenance because access controls are too broad or difficult to manage granularly?If you find yourself answering "yes" to any of these questions, it's a strong indicator that your current security architecture may be hindering your operational goals rather than helping them. In that case, it’s time to explore a different model.A new way forward: Improve uptime with modern securityUptime truly is a core business metric directly impacting production and revenue. The old ways of doing things—with their tangled rules, aging hardware, and manual processes—just weren't designed to handle the demands of agile operations, connected devices, and critical vendor access. Today’s solutions offer tangible benefits that directly support your manufacturing goals and don’t require ripping and replacing your entire infrastructure or scheduling disruptive downtime for every security change. A key benefit of modern internal security is its ability to minimize lateral threat spread. If malware or a breach does somehow reach one machine, smart segmentation ensures it stays contained. This is vital for protecting the rest of the network from cascading failures and safeguarding the production environment. And lightweight, agentless models let you upgrade without taking critical systems offline. Security then becomes an enabler—not a blocker—for uptime, modernization, and vendor agility. Making security a proactive enabler for your operational uptime is within reach. It requires rethinking old assumptions and embracing approaches designed for the modern factory floor.
↧